The engineers did "street work"
Project leader Yutaka Kubo recalls the start of the new Fazer development:" We journeyed to secondary roads in Italy, France, and Germany to see for ourselves the actual conditions Fazer 600 is used in, and listened to the actual voices of riders. From all this, we tried to extract the essential elements that would be necessary to build a "next-generation middleweight sport bike that surpasses the expectations of consumers." What we came up with was a bike concept that would combine super-sport performance and excitement with the relaxed riding style and character of a street sport bike. We believed that the next-generation Fazer should be a bike that is fast, not only when you rev the engine, but also fast when you go through the curves without too much traction on the rear wheel, and we worked on each of the parts accordingly. This is the reason, for example, that we chose to increase the rear-wheel drive-force (see next page)."

The development team indeed always had the sporty and excitement aspects in their minds. This first real model change of Fazer needed to be a big step ahead, and the priority set was to redefine "High Performance" in a new context and not simply make a super-sport machine with a higher handlebar. Focusing on a rider friendly high technology solution seemed more appropriate to describe the development direction, rather than "the more technology is better" approach.

Don't misunderstand the term "friendly" as soft or indifferent. The new Fazer is a bone to bone sports bike. But it is designed for public road and it makes the life of its rider as pleasant as possible in the daily situations you have to put up with in today's traffic!

GROWING DEMAND: Yamaha FZ6 - A High-Tech Naked Middleweight

The demand for naked middleweights is extremely strong in Europe - particularly in France and Italy - and in response to this growing market sector, Yamaha launches FZ6 for 2004.

The focus of development

1. Engine character with priority on middle range and no sacrifice in high revving capability

• Engine developed directly from the YZF-R6
• Fuel injection
• Maximum power output 72kW (98PS) to improve character in the low- and mid-speed range

The aims of engine development were to achieve both "an engine feeling with the kind of middle-speed range acceleration and smooth, powerful revving all the way up to the high-speed range". In order to achieve both an emotional engine feeling and ease of use, the new Fazer saw an engine developed directly from that of the 2003 model YZF-R6. Almost all of the basic specs and parts that contribute to the engine performance, including the bore x stroke the shape of the combustion chamber, the lightweight forged pistons, the identical spec intake/exhaust valves and the crank shaft are all the same as those of the YZF-R6 engine. Meanwhile, in order to achieve an engine character, that suits daily life in today's traffic, the design of the cam profile has been changed (modified opening degree and lift mass) along with the settings of the intake duct length and diameter. The maximum power output of this engine has been set at 72kW (98PS), which is reached at a rpm of 12,000. The maximum torque has been set at 10,000 rpm.

Yamaha's first group injection type fuel injection system offers an outstanding response and fuel economy with an optimum in intake/exhaust efficiency (volumetric efficiency). It is extremely compact and has a stunning simplicity of its sensing and fuel supply system. The remaining five sensors include:

1. the crank rpm sensor
2. the intake pressure sensor
3. the intake temperature sensor
4. the coolant temperature sensor
5. and the throttle position sensor

Down-draft intake and optimized air cleaner duct design gains the best possible performance from the fuel injection system. Particularly in the design of the air cleaner duct, the latest acoustics analysis technology was employed to get a very pleasing intake sound, including a harmonizing effect with the exhaust sound. (The adoption of a down-draft intake design also affords greater freedom in designing the riding position that is moved more forward.)

The throttle pulley is an eccentric type that functions progressively with regard to the degree of accelerator opening to give good control from idling into the lower speeds, contributing to the "mid-speed range acceleration".

2. Cornering character, which enables an effortless riding on winding country lanes

• Super-lightweight, high rigidity aluminium die-cast frame using Yamaha's unique CF Die Casting Technology
• Increased rear wheel drive force by improving the torque character and optimized transmission gear ratios
• A front wheel weight distribution ratio of 51% by revising the machine dimensions and moving the battery farther forward
• Optimized suspensions (43mm diameter high rigidity inner tubes for the front fork, lightweight Monocross rear suspension)
• New tire sizes. (Change front 110/70 ZR17 M/C to 120/70 ZR17 M/C, and rear 160/60 ZR17 M/C to 180/55 ZR17 M/C.)

For an ideal combination of light weight and good rigidity, the new Fazer is equipped with an aluminum die-cast frame produced with Yamaha's exclusive "CF Die Cast Technology". It is the first time that a die-cast aluminum frame has been used on a production motorcycle in this class.
This method allows to simplify the frame structure since there are no welding spots and enabling a two-part (right-left) structure that is simply bolted together at the head pipe assembly in the front and the pivot assembly in the rear. This lightweight frame and other features count for a reduction in equipped weight compared to the existing Fazer of approx. 7 kg.

The engine is mounted to the frame with of a 5-point rigid mount system which makes the engine a stressed member in the frame.

All new dimensions (including long swingarm design) count for superior running and handling performance. The wheelbase was set to 1,438 mm (previous Fazer:1,415 mm) while the caster angle was opened from 24 to 25 degrees and the trail increased from 88.6 mm to 97.5 mm. A very important feature is the longer rear swingarm, which has been lengthened from 516.5 mm to 590 mm. As a result, the effect of the reaction force from the road on the chain tension has been reduced to a minimum, which results in increased running stability.

These new dimensions, along with the adjustment in the engine position and the movement of the battery farther forward (under the fuel tank, short of the head pipe) has made it possible to give the front wheel a 51% share of the weight distribution (49% on existing Fazer). This is one of the important points contributing to the new Fazer's great drivability.

The new engine position brings the crank axis 10mm farther to the rear and 5mm higher than that of the existing model, which brings the engine's center of gravity even closer to the machines roll axis. In combination with the new frame and its dimensions, the rider feels one with his machine.

The 43mm front fork is the same size as on the Fazer 1000 (41 mm on existing Fazer 600). The result is excellent shock-absorption qualities and good front wheel road-contact feeling. To accommodate this, the pitch in the fork has been increased from 190 mm to 210 mm. Furthermore, the handlebar crown is now a single cast aluminum unit with the upper bracket.
The Monocross rear suspension with its optimized damper valve and the oil passages design, have given it a function equivalent to a link-equipped suspension.
With its sport-type settings, the rear wheel travel could be even increased to 130 mm (10 mm more than before).

3. Light and nimble handling (even in traffic jams and around-town riding)

• Handlebar turning angle of 35 degrees (minimum turning radius of 2.8m)
• Greater freedom of riding position by moving the hip point 8mm father forward

The new positioning of the center of gravity plus the new geometry enabled us to move the riding position. Compared to the existing model, the hip point has been moved forward 8mm. Combined with the additional seat freedom this enables greater freedom for riding position.

The seat with its dimple-finish cover reduces the ease of slipping and at the same time has high quality appearance.

A 35-degree handlebar turning angle for greater maneuverability in tight traffic and city riding became possible by optimizing both the fuel tank design and cowling.

4. New styling and function in line with concept

• Aluminium frame with excellent exterior appearance using Yamaha's unique CF Die Casting Technology
• "Up-swept muffler" exhaust pipe layout
• New windscreen design
• Immobilizer system to prevent theft

The new windscreen is designed to provide the rider with good wind protection while also producing minimum turbulence and wind noise. This screen surrounds the front of the body cowl and creates a dashboard appearance from the rider's point of view, with the liquid crystal meter panel and the integrated tachometer and speedometer in the middle.

On its center portion the cowl has two U shaped visors positioned to create an escape for the air flow which minimizes the swirl back against the rider. The overlap effect of the visor and cowl parts also give a unique and appealing visual impression.

The new twin headlights follow the family image of the R - series.

High exhaust efficiency with a 4-into-2-into-1 "up-muffler" has an impressive look. And a connecting pipe between No. 2 and No. 3 cylinder produces an outstanding exhaust pulse effect too. The pipe lengths, the silencer expansion chamber and the size of each pipe of course contributes to the wide power band of this engine.

New colour application technique maximizes the shine effect of metallic flake on parts including the front fender, the upper portion of the cowling and the seat cowl. This technique produces a near mirror-like shine and sense of depth.

5. Environment & maintenance friendliness

• Fuel injection to achieve ideal air/fuel settings for excellent fuel economy and optimized performance of the engine at all altitudes
• New Yamaha Air Induction System
• Metal honeycomb catalytic converter
• Low oil consumption with adoption of direct-plated cylinders

The Yamaha Air Induction System re-burns the un-combusted fuel as a first step in the exhaust to clean emissions.
The exhaust gas then undergoes further cleaning of toxic elements through a catalytic converter (with a metal honeycomb coated with titanium and Rhodium in a stainless steel box) positioned near the end of the exhaust pipe. The Fazer clears the EU-2 emissions standards by large margins. To look at numbers: it produces emissions equivalent to just 30% of the EU-2 regulation value for CO, 65% for HC and 40% for NOx.

The same liner-less direct plated cylinder as the YZF-R6 (ceramic composite plating) eliminates different heat expansion rates of the cylinder block, and improves heat dissipation, to achieve an optimum rigidity and greater accuracy in cylinder shape. This combined with the optimized piston ring design reduces piston motion resistance and oil consumption. 

Colour versions 2004

Click to enlarge.